| quote | Originally posted by Larryinkc: I used stainless butt weld close 90 degree pipe fittings on my 3800 exhaust, the shop welded 2 of them to make a 180 degree bend. It worked out great. Another option is an exhaust donut, you just cut out whatever bend you need. I also used V band clamps in case I ever need to remove the exhaust.
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Ditto.
With pre-bought bends (available in rather tight radii), and butt welding, you don't need a tubing expander, nor a bender.
Also, lap joints take up a certain amount of pipe length; it's easier to package butt welds where space is at a premium.
I found that 180° bends are the most versatile, since they include a bend, and include a straight segment on each leg which is often handy.
Cut and trim the bends until they follow the required path. Work from one end to the other, or from both ends, meeting in the middle.
I find it's good to work from one end to the other, or to work from opposing ends and make both sides meet in the middle.
My exhaust in progress:
Start with masking tape/Sharpie, tack as you become certain of things, and eventually finish weld.
OP, in your place, I would buy 2 or 3 (to allow for scrap) 180° U-bends, then hand it to the exhaust shop, and ask them to make it work with the supplied bends and butt welding.
Said exhaust shop probably needs to be the fancy kind of place that TIG welds everything, not Mister Muffler with aluminized crush-bends.
[This message has been edited by pmbrunelle (edited 11-06-2020).]